Composite body armor

ABSTRACT

Apparatus for protecting an individual from oncoming projectiles comprises a hardened steel plate; a support member supporting the hardened steel plate against the body of the individual; a plastic member; and an armor fiber secured to the plastic member, the armor fiber and said plastic member forming an interface layer, the interface layer being secured to the hardened steel plate at a position where the hardened steel plate is positioned between the interface layer and the body of the individual to be protected.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of Provisional Patent ApplicationNo. 62/077168, filed Nov. 7, 2014, and provisional patent applicationNo. 62/056483 filed Sep. 27, 2014, the disclosures of which are herebyincorporated herein by reference.

TECHNICAL FIELD

The invention relates to apparatus and methods for providing a measureof protection from handheld weapons to personnel in peacekeeping,policing and combat roles.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

(Not applicable)

BACKGROUND OF THE INVENTION

Today, a growing part of the globe is becoming increasingly unstable anddangerous. Military personnel and police officers are exposed to greaterrisks as stabilizing forces attempt to maintain peace and combatterrorists who favor surprise and ambush-style guerilla tactics. Much ofmodern combat takes place in urban environments where the norm is thatengagements take place at extremely close range, often with combatantsintermixed with a civilian population. This means that military andpolice are often attacked by surprise and often by unseen forces. Thisalso means that adversary fire can originate from all directions and inrapid succession, resulting in the human body needing to withstandmultiple impacts within a short period of time, sometimes on the orderof a few seconds.

The problem is complicated by the proliferation of increasingly highpowered rounds and the weaponry to deliver projectiles of unprecedentedpower. Due to such increased power, the trend has been toward heavierprotective gear, and AR500 steel plates have seen increased use.However, despite the relative effectiveness of AR500 steel, protectivegear incorporating the same is very heavy, compared to that made fromother materials, such as Kevlar® fabrics, ceramic plates and the like.Accordingly, there exists a need for more formidable body armorprotection having relatively low weight to keep personnel safe whilestill enabling them to do their jobs under such conditions, but withoutcarrying excessive weight.

The National Institute of Justice certifies body armor at variousprotective levels with a standard that defines an armor plate'sprotective capability. Most armor used by police and military fall intothe category of NIJ Level IIIA, NIJ Level III, or NIJ Level IV. NIJLevel IIIA is certified to stop large caliber pistol rounds such as a0.44 magnum, which are very powerful handgun rounds but not as powerfulas most rifle rounds. NIJ Level III is a higher rating than NIJ LevelIIIA and is certified to stop the more powerful, but non-armor piercing,rifle rounds such as the 7.62 mm steel jacketed bullets common to mostmilitary assault rifles. NIJ Level IV is an even higher rating than theNIJ Level III and is certified to stop the even more powerful 0.30caliber armor piercing rifle rounds commonly found in sniper rifles.These rounds have the same diameter projectiles as their less powerfulnon-armor piercing counterparts, but tend to travel faster due to theuse of more or more powerful propellant, or have solid steel cores whichincrease the likelihood of penetrating armor.

Modern body armor is commonly available in a soft or flexible formfashioned into vests or jackets or even full armored suits, as well asin the form of hard “trauma” or “ballistic” plates. Ballistic plates aresized to protect a specific portion of the human body, typically 10″×12″to protect the chest area, but can be of any size. Ballistic plates areheld in position over vital areas when they are inserted into ballisticplate pockets typically found in modern body armor. It is also common tosee ballistic plates inserted into tactical vests or “plate carriers” asthey are often called. Plate carriers are unarmored vests or harnessesthat are typically made from nylon or similar material and incorporatingpockets to hold ballistic plates, as well as other design features toprovide for the attachment of gear or equipment. Vests do not offer asmuch protection as full body armor combined with ballistic plates,however only using the ballistic plates for protection of the torso, themost critical vital areas are protected and substantial weight savingsare achieved.

Ballistic plates can be made out of a number of materials. Flexibleplates, for example, are commonly made of high tensile strength denselywoven fibers, such as those sold under the trademark Kevlar or ultrahighmolecular weight polyethylene fibers sold under the trademarks Spectraand Dyneema. Rigid plates may comprise steel, or, or, alternatively, avariety of ceramic based materials may be employed. Ceramic basedmaterials may include such compounds as aluminum oxide and siliconcarbide. Ceramic ballistic plates are the most common and are producedin many countries and under many different names.

Fibrous ballistic plates, such as those made of poly-para-phenyleneteraphthalamide (e.g. Kevlar®) fibers, have the advantage of being verylight weight for the protection provided. They absorb energy and stopbullets by the mechanism of the stretching of the fibers. Common“bulletproof” vests such as those comprising Kevlar® material functionin this manner. Typically, protective articles made of Kevlar® do notprovide protection above NH Level IIIA. Because protective gear made ofKevlar® is not rigid, when a bullet hits, but does not penetrate theKevlar®, percussive impact energy can still pass through to the bodycausing secondary damage as the Kevlar® bends, stretches and displacesto absorb the bullet's impact. Kevlar® also has the disadvantage of alimited shelf life as the fibers can break down due to wear and tear, orenvironmental ultraviolet exposure. Kevlar® can also be easily cut bydebris or shrapnel.

Steel ballistic plates can be very strong, and the thicker the steel,the stronger the ballistic plate becomes. Steel is a heavy material,however, and it is very uncommon for steel ballistic plates to exceed NHLevel III due to the weight of a sufficiently thick steel plate. Steelstops bullets by being rigid enough and thick enough to deflect incomingbullets and fragments, or shatter an incoming bullet into shrapnel.Steel does not break down as easily under normal environmental exposurecompared to Kevlar®, but can still suffer marginal deterioration due torust. A more serious shortcoming is the likelihood of bullets (or bulletfragments) being deflected from steel ballistic plates after impact.This can pose a risk of secondary injury if the ricocheted fragment hitsan individual in an unarmored part of the body.

Ceramic ballistic plates provide a great deal of protection for theirweight and are commonly produced to NH Level IIIA, NIJ Level III, and,significantly, NIJ Level IV standards. Ceramic ballistic plates maycomprise a variety of materials, but aluminum oxide and silicon carbideare the most common.

Ceramic based trauma plates absorb the energy of and, when effective,stop or greatly reduce impact speeds of bullets using anablative/fracture process. The relative functions of the ablative(ballistic impact energy is dissipated through the loss of armormaterial) and fracture (ballistic impact energy is dissipated throughfracturing of armor material) characteristics may be varied in thematerial design.

Although this dual ablative/fracture energy absorption mechanism allowsceramic ballistic plates to stop very powerful bullets, it has thedisadvantage that every impact weakens the armor. Moreover, damage ispropagated from the point of impact. This means that after the firstshot, every additional bullet is more likely than the previous to punchthrough a ceramic ballistic plate, especially if it hits close to thelocation of a previous impact.

Perhaps more seriously, even “micro” impacts, stresses and concussionsfrom nearby explosions, and general wear and tear will deteriorateceramic armor. Even more serious damage and degradation of the armorcapability of a ceramic ballistic plate will be done by low impactconcussion, such as that due to ballistic and non-ballistic debris.Thus, damage can cause small fractures and weaken the ceramic ballisticplate over time. Such damage may not be visible to the eye. Accordingly,ceramic ballistic plates can be weakened without the wearer knowing thatprotection has been compromised. This resulted putting the wearer atincreased risk. Because of this risk it is common for ceramic ballisticplates to be regularly x-ray scanned to check for deterioration. The USMilitary regularly cycles out older ceramic ballistic plates every 3years or so, even if the ceramic ballistic plate has never seen combat.

Although most commonly used by the military, ceramic ballistic platesare the most expensive option for protection, partly because of theinitial cost of the material and partly because of the cost of a properretirement schedule.

Given the above limitations of conventional constructions, ambushtactics and the use of explosives, which are commonplace in modern urbancombat, creates a need for a ballistic plate that does not easily breakdown through concussive impact and general wear and tear. A need existsfor a ballistic plate that can withstand long term use in less thanideal conditions, and will provide maximum protection from multiple hitsfor a reasonable weight, and not require any special care or maintenanceto insure reliability.

SUMMARY OF THE INVENTION

In accordance with the invention, a protective armor plate is provided.This is achieved through the use of a composite trauma plate with asteel base for strength, combined with an absorption layer to dissipateballistic impact energy, and both contained within a protectiveencasement layer. The absorption layer may comprise Kevlar® para-aramidsynthetic fiber. Other materials, such as polyparaphenelynebenzobisthiazole film, a liquid crystal-like material similar to Kevlar®may also be employed in accordance with the present invention. It iscontemplated that such film may be formed by calendaring, extrudingand/or tentering to form a layer with good uniaxial strength, thatindividual layers may be laminated with their uniaxial directions ofstrain oriented in a plurality of directions, for example every 45°.

The inventive protective device protects an individual from oncomingprojectiles and comprises a substantially rigid member having a lengthand a width sufficient to overlie a portion of the body of theindividual to be protected. The substantially rigid member has a frontside oriented toward an incoming projectile and a reverse or back sidein facing relationship to the portion of the body of the individual tobe protected. The substantially rigid member is configured to spread outenergy from the incoming projectile to a plurality of points on theportion of the body of the individual to be protected. An energyabsorbing member is supported by a support member on the substantiallyrigid member at a position where energy from an oncoming projectile istransferred to and absorbed by the energy absorbing member.

BRIEF DESCRIPTION THE DRAWINGS

The operation of the invention will become apparent from the followingdescription taken in conjunction with the drawings, in which:

FIG. 1 is a cross-sectional view of an armor plate constructed inaccordance with the present invention;

FIG. 2 is a cross-sectional view of the foundation layer in anembodiment of the present invention;

FIG. 3 illustrates in cross-section the interface layer in an embodimentof the present invention;

FIG. 4 is a cross-sectional view according to the present invention ofan alternate embodiment of an interface layer;

FIG. 5 illustrates in cross-section still another alternative embodimentof the present invention;

FIG. 6 illustrates in cross-section yet still another embodiment of theinventive protective plate;

FIG. 7 illustrates in cross-section yet another embodiment of theinvention;

FIG. 8 illustrates in cross-section still yet another alternativeembodiment of the present invention;

FIG. 9 illustrates an alternative embodiment of the present inventiongenerally comprising a multilayer sandwich protective plate;

FIG. 10 illustrates in perspective a pair of plates as they would bepositioned around the chest during use;

FIG. 11 illustrates the shape of a typical armored plate;

FIGS. 12-49 schematically depict alternative embodiments employing ofthe invention;

FIGS. 50-53 schematically depict improved methods for applying aprotective encasement layer to better weather seal an armor plate;

FIG. 54 illustrates an improved method for applying spall protection;

FIG. 55 illustrates an improved method for applying Kevlarreinforcement; and

FIGS. 56 and 57 schematically illustrate a further alternativeembodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIG. 1, an overview of an armor piercing resistantcomposite hard ballistic plate constructed in accordance with theinvention may be understood. The inventive and armor piercing resistantcomposite hard ballistic plate 10 comprises a first plate whichfunctions as a foundation layer 12, the second plate which functions asan interface layer 14, and an encapsulation layer 16. Foundation layer12 has an outer foundation layer surface 18 and an inner foundationlayer surface 20, which layers are parallel to one another. Interfacelayer 14 is meant to receive the initial impact of an incomingprojectile, whereas foundation layer 12 rests against the chest of theindividual wearing the vest in which ballistic plate 10 is held.Foundation layer 12 is made from a rigid material, for example hardenedsteel such as ¼ inch thick AR500 steel in the preferred embodiment,although other rigid materials, or combinations of materials, such asrigid metals, polymers, ceramics and laminates. Such materials can alsobe used to form a desired shape, in the case of the embodimentillustrated in FIG. 1 being a flat member 10 inches by 12 inches. Thismay be slightly curved off the vertical plane to comfortably fit atop asurface on the left or right side of the torso of the human body.

Interface layer 14 is made from non-rigid layers of materials intendedto reduce the velocity of an incoming projectile and help trapfragmentation and ricochets within its layers, for example Kevlar andrubber in the preferred embodiment, although layers of other non-rigidmaterials, including but not limited to foam, woven carbon fiber andpolymers such as ultra high molecular density polyethylene, as well aspolyparaphenelyne benzobisthiazole film may be used. Interface layer 14comprises an outer interface layer surface 22 and an inner interfacelayer surface 24 which are, for example, parallel to one another.

Inner interface layer surface 24 is affixed to outer foundation layersurface 18 using an adhesive 26, thus connecting interface layer 14 tofoundation layer 12 forming a composite hard plate assembly 28.Composite hard plate assembly 28 is encased within an encapsulationlayer 16. Encapsulation layer 16 protects and environmentally sealscomposite hard plate assembly 28, and is made out of a rubberizedmaterial in the preferred embodiment, but any preferably watertightenvironmentally sealing material the does not substantially degrade overtime is appropriate.

Referring to FIG. 2, a detailed understanding of a preferred embodimentof foundation layer 12 may be understood. In this embodiment, foundationlayer 12 comprises a rigid base 30 and a shock absorbing layer 32. Rigidbase 30 comprises an outer base surface 34 and an inner base surface 36.Rigid base 30 is made from a rigid material, for example ¼ inch thickAR500 steel in the preferred embodiment, although other rigid materials,or combinations of materials, such as rigid metals, polymers, andlaminates can also be used. Shock absorbing layer 32 comprises an outershock absorbing layer surface 38 and an inner shock absorbing layersurface 40. Shock absorbing layer 32 helps to diffuse impact energyagainst a human body and is made from a compressible material, forexample ⅛″ foam rubber in the case of the preferred embodiment, but canbe made from any compressible polymer.

Outer shock absorbing layer surface 38 is affixed to inner base surface36 using an adhesive 42 in such a configuration that, optionally, nopart of outer shock absorbing layer surface 38 or inner base surface 36are exposed. Interface layer 14 is affixed to outer base surface 34 byadhesive 26 to complete formation of composite hard plate assembly 28.As in the FIG. 1 embodiment, composite hard plate assembly 28 is encasedwithin an encapsulation layer 16 for environmental protection.

Referring to FIG. 3, a detailed understanding of interface layer 14 maybe understood. Interface layer 14 comprises a compression layer 44, afibrous mesh layer 46, and an entrapment layer 48, which underliesencapsulation layer 16. Entrapment layer 48 may be made of a highfriction polymer and have a thickness of ⅛ inch. Compression layer 44comprises an inner compression surface 50 and an outer compressionsurface 52 which are optionally parallel to one another. Compressionlayer 44 is made out of a compressible material, for example ⅜″ rubberin the preferred embodiment, but can also be made using, but not limitedto varying thicknesses of foam, foam rubber, neoprene, or anycompressible polymer. Inner compression surface 50 affixes to outerfoundation layer surface 18 by means of adhesive 26.

Fibrous mesh layer 46 comprises an outer mesh surface 54 and an innermesh surface 56 which may be roughly parallel to one another. Inner meshsurface 56 is affixed to outer compression surface 52 using adhesive 26,in such a way that fibrous mesh layer 46 is positioned atop, optionallyrubber, compression layer 44. Fibrous mesh layer 46 is made out of amesh or weave of high tensile strength fibers, such as Kevlar in thedisclosed embodiment, though other high tensile strength polymers suchas, but not limited to, ultra high molecular density polyethylene, orhigh tensile strength non polymer fibers such as, but not limited to,carbon fibers. Fibrous mesh layer 46 may be made of a polymeric materialwhich stretches when absorbing impact energy from an incoming bullet.Compression layer 44 supports fibrous mesh layer 46 during a bulletimpact and assists with energy dissipation.

Entrapment layer 48 comprises an outer entrapment surface 58 and aninner entrapment surface 60 which are parallel to one another. Innerentrapment surface 60 is affixed to outer mesh layer 54 using adhesive26 such that entrapment layer 48 is positioned atop fibrous mesh layer46. Entrapment layer 48 is made out of a high friction polymer, such asdense rubber in the preferred embodiment, though entrapment layer 48could be made out of other durable, high friction polymers such as, butnot limited to, a dense foam or foam rubber. Entrapment layer 48 helpsprotect fibrous mesh layer 46 from incidental and non-ballistic damageas well as prevents wear and tear.

Entrapment dimples 62 are affixed to outer entrapment surface 58, and inthe preferred embodiment are made from the same dense rubber used inentrapment layer 48 and integrally made with entrapment layer 48, butcould be made out of other high friction polymers such as, but notlimited to, a dense foam rubber. Dimples 62 cause incoming bullets andprojectiles that connect with entrapment surface 58 to interactdifferently due to an uneven surface as opposed to a smooth surface.

FIG. 4 is a similar but alternate embodiment of interface layer 14 foundin the embodiment of FIGS. 1-3. Where practicable, in the variousdisclosed embodiment, parts having similar or analogous functions arenumbered with numbers which are multiples of 100 different fromcorresponding or analogous parts in other embodiments.

Referring to FIG. 4, a detailed understanding of an interface layer 114may be understood. Interface layer 114 comprises a number of compressionlayers 144, a number of fibrous mesh layers 146, and an entrapment layer148. Compression layers 144 comprise inner compression surfaces 150 andouter compression surfaces 152 which are parallel to one another.Compression layers 144 are made out of a compressible material, forexample ⅛″ rubber in the alternate embodiment, but can also be madeusing, but not limited to varying thicknesses of foam, foam rubber,rubber, or any compressible polymer. A bottom inner compression surface151 affixes to outer foundation layer surface 118 by means of adhesive126.

Fibrous mesh layers 146 comprise outer mesh surfaces 154 and inner meshsurfaces 156 which are parallel to one another. Inner mesh surfaces 156are affixed to outer compression surfaces 152 using adhesive 126, insuch a way that fibrous mesh layers 146 are positioned atop compressionlayers 144. Additionally, inner compression surfaces 152 are affixed toouter mesh surfaces 156 below, thus creating multiple layers. Fibrousmesh layers 146 are made out of a mesh or weave of high tensile strengthfibers, such as Kevlar in the preferred embodiment, though other hightensile strength polymers such as, but not limited to, ultra highmolecular density polyethylene, or high tensile strength non polymerfibers such as, but not limited to, carbon fibers. Fibrous mesh layers146 stretch when absorbing impact energy from an incoming bullet.Compression layers 144 support fibrous mesh layers 146 during a bulletimpact and assist with energy dissipation.

Entrapment layer 148 comprises an outer entrapment surface 158 and aninner entrapment surface 160 which are parallel to one another. Innerentrapment surface 160 is affixed to upper outer mesh layer 155 usingadhesive 126 such that entrapment layer 148 is positioned atop fibrousmesh layer 146. Entrapment layer 148 is made out of a high frictionpolymer, such as dense rubber in the preferred embodiment, thoughentrapment layer 148 could be made out of other durable, high frictionpolymers such as, but not limited to, a dense foam or foam rubber.Entrapment layer 148 helps to protect fibrous mesh layer 146 fromincidental and non-ballistic damage as well as to prevent excessive wearand tear.

Entrapment dimples 162 are affixed to outer entrapment surface 158, andin the preferred embodiment are made from the same dense rubber used inentrapment layer 148, but could be made out of other high frictionpolymers such as, but not limited to, a dense foam rubber. Dimples 162cause incoming bullets and projectiles that connect with entrapmentsurface 158 to interact differently due to an uneven surface as opposedto a smooth surface.

Referring to FIG. 5, an overview of another alternate preferredembodiment of an armor piercing resistant composite hard ballistic plate210 may be understood. An armor piercing resistant composite hardballistic plate 210 comprises a foundation layer 212, an interface layer214, and an encapsulation layer 216. Foundation layer 212 is made from arigid material, for example ¼ inch thick AR500 steel in the alternatepreferred embodiment, although other rigid materials, or combinations ofmaterials, such as rigid metals, polymers, and laminates can also beused to form a desired shape, in the case of the alternate preferredembodiment being a flat member 10 inches by 12 inches which is slightlycurved to comfortably fit atop a surface of a torso of a human body,such as the chest. Foundation layer 212 comprises an outer foundationlayer surface 218 and an inner foundation layer surface 220 which areparallel to one another.

Interface layer 214 is made from non-rigid layers of materials intendedto reduce the velocity of an incoming projectile and help trapfragmentation and ricochets within its layers, for example Kevlar andrubber in the alternate preferred embodiment, although other non-rigidmaterials including but not limited to foam, carbon fiber, and polymerssuch as ultra high molecular density polyethylene may be used. Interfacelayer 214 comprises an outer interface layer surface 222 and an innerinterface layer surface 224 which are parallel to one another.

Inner interface layer surface 224 is affixed to outer foundation layersurface 218 using an adhesive 226, thus connecting interface layer 214to foundation layer 212 forming a composite hard plate assembly 228.Composite hard plate assembly 228 is encased within an encapsulationlayer 216. Encapsulation layer 216 protects and environmentally sealscomposite hard plate assembly 228, and is made out of a rubberizedmaterial in the preferred embodiment, but any watertight environmentallysealing material the does not degrade in the elements would be used.

Composite hard plate assembly 228 is provided with an raised labelingsystem 230 made from, in the alternate preferred embodiment, arubberized material, similar to the rubberized material referenced inembodiment 1-3 entrapment layer 48, but can be made out of otherdurable, high friction polymers such as, but not limited to, a densefoam or foam rubber. Raised labeling system 230 is affixed to outerinterface layer surface 222, using adhesive 226, such that embossedlabeling system 230 protrudes from, and is distinguishable from,composite hard plate assembly 228, such that a clearly visible threedimensional embossing effect 232 is created which is distinguishablethrough encapsulation layer 216, and may portray a symbol, alphanumericdesignation or the like.

Hidden within encapsulation layer 216 is a radio-frequencyidentification chip 234, which is affixed to a side surface 236 ofcomposite hard plate assembly 228, by means of adhesive 216, such thatradio-frequency identification chip 234 does not come in contact with,either outer interface layer surface 222, or inner foundation layersurface 220, thus reducing the odds of radio-frequency identificationchip 234 being damaged should multiple armor piercing resistantcomposite hard ballistic plates 210 be stacked one upon another.Radio-frequency identification chip 234 is coupled with a uniqueidentification 238 that distinguishes any particular armor piercingresistant composite hard ballistic plate 210 from other similar armorpiercing resistant composite hard ballistic plates 210. The coupling ofradio-frequency identification chip 234 with unique identification 238allows individual armor piercing resistant composite hard ballisticplates 210 to be scanned electronically for purposes such as inventorycontrol and tracking.

Chip 234 may be an active RFID chip, a passive RFID chip, or any otherdevice capable of acting as a transponder. While passive ISAM band chipsoperating in the 865-868 MHz range in Europe and the 902-928 MHz rangein North America are low in cost, typically in the range of $0.15 each,other technologies may be more appropriate, including active devices,devices operating in the 3 to 10 GHz range, devices acting in lowermicrowave frequency ranges, UHF devices of the type operating in therange of about 433 MHz, as well as high-frequency and low-frequencydevices. Choice depends upon cost, range desired, and data speedrequired. However, in accordance with the invention, relatively slowdata speeds will likely provide substantially acceptable functionality.

Referring to FIG. 6, an overview of an alternate armor piercingresistant composite hard ballistic plate may be understood. An armorpiercing resistant composite hard ballistic plate 310 comprises afoundation layer 312, an interface layer 314, and an encapsulation layer316. Foundation layer 312 is made from a rigid material, for example ¼inch thick AR500 steel in the preferred embodiment, although other rigidmaterials, or combinations of materials, such as rigid metals, polymers,and laminates can also be used to form a desired shape, in the case ofthe preferred embodiment being a flat member 10 inches by 12 incheswhich is slightly curved to comfortably fit atop a surface of a torso ofa human body. Foundation layer 312 comprises an outer foundation layersurface 318 and an inner foundation layer surface 320 which are parallelto one another.

A spallguard 313 is coupled to foundation layer 312, spallguard 313encompassing foundation layer 312 on all sides, by weld 315, which is atack weld in the preferred embodiment, but can alternatively be anothertype of weld such as, but not limited to, a continuous weld or anintermittent weld, at angle 317 away from outward foundation layersurface 318, a 40 degree angle in the preferred embodiment, though anyangle such that projectiles sliding across outer foundation layersurface 318 impact spallguard 313 and get stopped or deflected in anoutwardly direction away from outer foundation layer surface 318, wouldwork. Spallguard 313 has an inward spallguard surface 319 and an outwardspallguard surface 321 that are parallel to one another and consistentwith angle 317.

Interface layer 314 is made from non-rigid layers of materials intendedto reduce the velocity of an incoming projectile and help trapfragmentation and ricochets within its layers, for example Kevlar andrubber in the preferred embodiment, although other non-rigid materialsincluding but not limited to foam, carbon fiber, and polymers such asultra high molecular density polyethylene may be used. Interface layer314 comprises an outer interface layer surface 322 and an innerinterface layer surface 324 which are parallel to one another.

Inner interface layer surface 324 is affixed to outer foundation layersurface 318, and outer spallguard surface 321, using an adhesive 326,curved to match angle 317, thus connecting interface layer 314 tofoundation layer 312 and spallguard 313, forming a composite hard plateassembly 328. Composite hard plate assembly 328 is encased within anencapsulation layer 316. Encapsulation layer 316 protects andenvironmentally seals composite hard plate assembly 328, and is made outof a rubberized material in the preferred embodiment, but any watertightenvironmentally sealing material that doesn't degrade in the elementswould be used.

Referring to FIG. 7, an overview of an alternate armor piercingresistant composite hard ballistic plate may be understood. An armorpiercing resistant composite hard ballistic plate 410 comprises afoundation layer 412, an interface layer 414, and an encapsulation layer416. Foundation layer 412 is made from a rigid material, for example ¼inch thick AR500 steel in the preferred embodiment, although other rigidmaterials, or combinations of materials, such as rigid metals, polymers,and laminates can also be used to form a desired shape, in the case ofthe preferred embodiment being a flat member 10 inches by 12 incheswhich is slightly curved to comfortably fit atop a surface of a torso ofa human body. As in the case of the other embodiments, thicker steelplate may be used and will result in better protection against incomingrounds. Foundation layer 412 comprises an outer foundation layer surface418 and an inner foundation layer surface 420 which are parallel to oneanother.

A spallguard 413 is coupled to foundation layer 412, spallguard 413encompassing foundation layer 412 on all sides, by weld 415, which is atack weld in the preferred embodiment, but can alternatively be anothertype of weld such as, but not limited to, a continuous weld or anintermittent weld, at angle 417 away from outward foundation layersurface 418, a 40 degree angle in the preferred embodiment, tough anyangle such that projectiles sliding across outer foundation layersurface 418 impact spallguard 413 and get stopped or deflected in anoutwardly direction away from outer foundation layer surface 418, wouldwork. Spallguard 413 has an inward spallguard surface 419 and an outwardspallguard surface 421 that are parallel to one another and consistentwith angle 417.

Interface layer 414 is made from non-rigid layers of materials intendedto reduce the velocity of an incoming projectile and help trapfragmentation and ricochets within its layers, for example Kevlar andrubber in the preferred embodiment, although other non-rigid materialsincluding but not limited to foam, carbon fiber, and polymers such asultra high molecular density polyethylene may be used. Interface layer414 comprises an outer interface layer surface 422 and an innerinterface layer surface 424 which are parallel to one another, and withinterface layer thickness 425 such that outer interface layer surface422 is flush with the outer most portion of spallguard 413.

Inner interface layer surface 424 is affixed to outer foundation layersurface 318, and outer spallguard surface 421, using an adhesive 426,said inner interface layer surface 424 curved to match angle 417, thusconnecting interface layer 414 to foundation layer 412 and spallguard413, forming a composite hard plate assembly 428. Composite hard plateassembly 428 is encased within an encapsulation layer 416. Encapsulationlayer 416 protects and environmentally seals composite hard plateassembly 428, and is made out of a rubberized material in the preferredembodiment, but any watertight environmentally sealing material the doesnot degrade in the elements would be used.

Referring to FIG. 8, an overview of an alternate preferred embodiment ofan armor piercing resistant composite hard ballistic plate 510 may beunderstood. An armor piercing resistant composite hard ballistic plate510 comprises foundation layers 512 with peripherally overlapping edges,a foundation bonding matrix 513, an interface layer 514, and anencapsulation layer 516. Foundation layers 512 are made from multiplepieces of rigid material, for example ¼ inch thick AR500 steel in thealternate preferred embodiment, although other rigid materials, orcombinations of materials, such as rigid metals, polymers, and laminatescan also be used to form a desired shape, in the case of the alternatepreferred embodiment being a complex curve.

Foundation layers 512 are encapsulated by foundation bonding matrix 513which serves to couple individual foundation layers 512 to one anotherforming a contiguous bonded foundation layer 515. Contiguous bondedfoundation layer 515 comprises an outer foundation layer surface 518 andan inner foundation layer surface 520 which may or may not be paralleldepending on the desired complex shape.

Interface layer 514 is made from non-rigid layers of materials intendedto reduce the velocity of an incoming projectile and help trapfragmentation and ricochets within its layers, for example Kevlar andrubber in the alternate preferred embodiment, although other non-rigidmaterials including but not limited to foam, carbon fiber, and polymerssuch as ultra high molecular density polyethylene may be used. Interfacelayer 514 comprises an outer interface layer surface 522 and an innerinterface layer surface 524 which are parallel to one another.

Inner interface layer surface 524 is affixed to outer foundation layersurface 518 using an adhesive 526, thus connecting interface layer 514to foundation layer 512 forming a composite hard plate assembly 528.Composite hard plate assembly 528 is encased within an encapsulationlayer 516. Encapsulation layer 516 protects and environmentally sealscomposite hard plate assembly 528, and is made out of a rubberizedmaterial in the preferred embodiment, but any watertight environmentallysealing material the does not degrade in the elements would be used.

FIG. 9 illustrates an alternative embodiment of the present inventiongenerally comprising a multilayer sandwich protective plate 610 ofpadding 611, ceramic 615, shock absorbing layer 617, foundation layerhardened steel plate 612, an interface layer 614, fibrous mesh layer 646and encapsulation layer 616.

Padding 611 may comprise any suitable padding material, such ascompressed fibers, soft foam rubber, feathers, or any other materialwhich would suffice to absorb the shock of impact between the chest ofthe wearer and the ceramic plate 615. Ceramic plate 615 may be made ofany material conventionally used to make ceramic bullet protectiveplates, as detailed above. Shock absorbing layer 617 may be made of anymaterial suitable to protect ceramic plate 615 from shocks that might betransmitted by the foundation layer hardened steel plate after it hasbeen impacted by projectile. Such material may be relatively dense foamrubber. Foundation layer hardened steel plate 612 may be a relativelythin layer of AR 500 hardened steel, for example 0.25 inches, or even0.125 inches. Interface layer 614 may be made of any material suitableto absorb projectiles impacting multilayer sandwich protective plate610, for example foam rubber. Fibrous mesh layer 646 may be made of anysuitable material, such as woven Kevlar fiber. Like in the otherembodiments, the amount of fiber may be comparable to that used inconventional all fiber so-called bulletproof vests. Encapsulation layer616 may be made of hard rubber to provide the encapsulation function ofthe encapsulation layers of the other embodiments described herein, andwould be made of similar materials.

The inventive multilayer sandwich protective plate 610 may be made usingthe techniques described above in connection with the other embodiments,and which are generally employed in assembling the various embodimentsof the invention disclosed herein.

The multilayer sandwich protective plate 610 has the advantage oflighter weight compared to the other embodiments. More particularly,part of the strength of protective plate 610 is provided by the AR 500hardened steel plate 612. The other primary protective layer is ceramicplate 615. The weight of the combination is somewhat lower than an allsteel plate. However, the multilayer sandwich protective plate 610 doesnot suffer from the problem of microfracture degradation, in so far asit is protected by shock absorbing layer 617 from vibrations caused byimpacts of projectiles against steel plate 612. Thus, impacts on steelplate 612 all have minimal effect on the integrity of ceramic plate 615,unless steel plate 612 is shattered, in which case ceramic plate 615provides a backup protective function.

FIG. 10 illustrates a pair of plates 10 as they would be positionedaround the chest of a wearer, and which may incorporate any of the abovestructures. FIG. 11 shows an alternative approach where a singleprotective member constructed in accordance with the present inventionis essentially placed over the center of the chest of the wearer andsubstantially covers the chest of the user to the extent usuallyprovided in the prior art.

In accordance with the invention, it has been discovered that,remarkably, soft rounds traveling at sufficient velocity, afterimpacting armor, for example personal protection body armor, appear tobe transferring momentum through a substantially inelastic collision andcausing hardened AR500 steel to fracture in a circular pattern, allowingthe bullet and a bullet shaped piece of AR500 steel to break through andadvance toward the individual being protected. Four sets of tests withnumerous samples in each group were conducted as are detailed below.Except where otherwise specified, foundation plates and foundation platecomponents, made of steel or aluminum used in the tests detailed hereinwere performed on 6″×8″ test sample plates. All AR500 steel platestested were ¼″ thick and the aluminum thickness, either ¼″ or ⅛″depending on the test, as detailed herein. The aluminum employed in thefabrication of the various embodiments described herein is referred toas 5052 aluminum plate and is available from numerous distributors.Typically, fabrication begins with large plates having a width dimensionof 48 inches, and a length dimension of either 96 inches or 120 inches.Kevlar® layers manufasctured by Infinity Composites in Ashtabula, Ohiowere employed in fabricating the various embodiments described herein.The Kevlar® fiber used was in the form of large rolls of woven material.The fibers used to make the material are produced by Dupont. Kevlar®fibers comprise an aramid fiber that is used by manufacturers who weavethe fabric into various patterns. The Kevlar fabric is given aspecification corresponding to the particular weight of the material ina square yard. In accordance with the invention, the heaviest knownmaterial, which has a specification of 14 ounces, was employed. Thepattern of the weave to produce the roll of Kevlar fiber employed in theembodiments disclosed herein is identified by the manufacturer as a 90degree, 4 strand, overlapping weave. Generally, such material isprovided in roll form, 50 inches wide and 150 yards in length. Testswere conducted using 5.56×45 mm, 55 grain, copper full metal jacket leadball rounds, travelling in excess of 3200 ft/sec. These rounds werechosen because they are a non-armor piercing bullet that was discoveredby the inventors to be consistently punching through bare ¼ inch AR500steel plates. As used in this specification, the term “bare” refers to aplate of AR 500 steel without laminations of Kevlar, aluminum or othermaterial on either side.

Test Group 1:

Test Group 1 involved Samples consisting of ¼″ AR500 steel plates withvarying amounts of Kevlar and foam layers affixed atop a the plate todetermine how effective various soft interface layer combinations are atreducing bullet penetration. Samples involving six layers of Kevlaroutperformed Samples involving two layers of Kevlar. Furthermore,Samples incorporating more foam outperformed Samples incorporating lessfoam. This was a surprising result in so far as the foam has minimalstopping power. However, in accordance with the invention, it ispostulated that it may be possible that thicker foam allows greaterstretching of the Kevlar with concomitant greater energy absorption.Effectiveness of the structure under test was determined by measuringthe size of the exit hole on the back end of the plate. A smaller exithole was viewed as indicative of less damage than a larger exit hole. Inevery case, however, the bullet was able to completely penetrate theSample to some degree. Additionally, in every case, all of the spall anddebris was captured by the interface layer indicating that front facing2 layers of Kevlar affixed atop a ⅛″ layer of foam affixed atop thefront face of a ¼″ AR500 steel plate was sufficient to prevent secondarydamage from spall and debris. By the front of a plate or plate assemblyis meant the side of the plate upon which a round is incident. Back ofthe plate would be adjacent the body of the individual being protected.Typical structures tested comprised 1) an interface layer forming thefront of the plate and received the first impact from an incoming round,and 2) a foundation layer) secured to and supporting the interfacelayer) designed to bear against the torso of an individual beingprotected. We were surprised at how well the rubberized encasementlayer, in this case Plastidip, was able to hold together and, for themost part, even appeared to reseal itself after initial penetration bythe bullet. This indicates a greater survivability of a soft interfacelayer than previously expected.

Referring to FIG. 12 it can be seen how Samples were tested, and theirstructure, which may be said generally to comprise an encapsulation orencasement layer 16 which envelops a target Sample 10 which protects anindividual 11. Encasement layer 16 may comprise Plastidip®, a plasticmaterial manufactured by Plastidip International. Encasement layer 16may be applied by spraying, brushing or dipping. Optionally, encasementlayer 16 may be deposited over a dimpled foam plastic strike facedeposited, or positioned and glued over surface 22 of interface layer14. Contained within the encasement layer, each Sample comprises aninterface layer affixed atop a foundation layer, with the foundationlayer comprising ¼″ AR500 steel plate. The only difference betweenSamples was the composition of the interface layer, the interface layerbeing a layer in the armor assembly which interacts with incomingbullets prior to an incoming bullets interaction with the foundationlayer. All Samples were shot with a 5.56×45 lead bullet traveling inexcess of 2800 ft/sec. For the purposes of testing, “Sample” is meant todesignate a inch by inch armor plate section with full thicknessconstituent elements constructed for test purposes. This armor platesection is believed to simulate the operation of full size personal bodyarmor, and further believed, with a high degree of confidence, to be atleast a reliable indicator of the relative strengths and weaknesses offull size armor. The various samples in the examples disclosed in thespecification were tested by mouthing the sample armor plate portionstructures as targets. All rounds, unless otherwise indicated, werefired from a distance of approximately fifteen meters. No repeatedrounds to the same plate, or the same location, unless otherwiseindicated, were fired.

Referring to FIG. 13, Sample A (interface layer comprising 6 layers ofKevlar affixed atop ¼″ foam) with the foundation layer comprising ¼″AR500 steel plate fired upon with a 5.56×45 lead bullet resulted incomplete penetration, that is relatively poor protection. In thisembodiment, as in all the other embodiments illustrated in FIGS. 13-49,Kevlar fabric of the type detail below was used. Likewise, in thisembodiment, as well as all other embodiments illustrated in FIGS. 13-49,all layers of material (whether Kevlar, steel, aluminum, foam, plastic,or other material) were secured to each other with using glue asspecified herein.

Referring to FIG. 44, Sample B: (interface layer comprising 2 layers ofKevlar affixed atop ⅛″ foam with the foundation layer comprising ¼″AR500 steel plate when fired upon by a 5.56×45 lead bullet resulted incomplete penetration or relatively poor protection.

Referring to FIG. 45, Sample C: (interface layer comprising twosublayers affixed atop one another, each sublayer comprising one layerof Kevlar 101 affixed atop a ⅛″ thick layer of foam 102 affixed atop afoundation layer 103 comprising ¼″ AR500 steel plate when fired upon bya 5.56×45 lead bullet resulted inrelatively poor protection.

Referring to FIG. 46, Sample D: (interface layer comprising 2 sub layersaffixed atop one another, sub layers comprising two layers of Kevlar 101affixed atop ⅛″ foam layer 102 with the foundation layer 103 comprising¼″ AR500 steel plate when fired upon by a 5.56×45 lead bullet resultedin relatively poor protection.

Referring to FIG. 47, interface layer comprising 1 layer of Kevlar 104affixed atop ⅛″ foam 105 affixed atop 2 layers of Kevlar affixed atop ⅛″foam affixed atop 1 layer of Kevlar 104 with the foundation layercomprising ¼″ AR500 steel plate, when fired upon by a 5.56×45 leadbullet resulted in relatively poor protection.

Referring to FIG. 48, Sample F (interface layer comprising 6 layers ofKevlar affixed atop ½″ foam with the foundation layer comprising ¼″AR500 steel plate when fired upon by a 5.56×45 lead bullet resulted incomplete penetration (but with a small hole) and thus relatively poorprotection.

Referring to FIG. 49, Sample G: (interface layer comprising 6 layers ofKevlar affixed atop ¾″ foam with the foundation layer comprising ¼″AR500 steel plate, when fired upon by a 5.56×45 lead bullet resulted incomplete penetration but with a small hole and thus relatively poorprotection.

Test Group 1 Conclusion: This test (described in connection with FIGS.13, 44 -49 was initiated when it was discovered that lead core bulletstraveling in excess of 2800 feet/second pose a significant risk to AR500steel plate foundation layers. It is believed that the inelasticcollision in soft lead rounds transfers momentum more completely to thesurface of the AR500 steel which, at sufficient bullet velocities causesthe stand-alone ¼″ AR500 steel to fracture and fail in a relativelyclean circle of the same size as the deformed lead bullet. In the caseof each of the samples, 7.62×39 and 7.62×54 steel core bullets (asopposed to the lead core bullets) were defeated. Samples using more foamperformed better than similar Samples using less foam probably becausethe thicker foam in the interface (front) layer allows Kevlar to stretchmore before the bullet hits the foundation (which is in contact withbody of person being protected) layer. What was surprising was that thevarious constructions of the interface layer, even constructions thathad passed level 4 armor piercing 30.06 (steel core) tests, still werenot able to prevent a 5.56 lead core bullet traveling in excess of 2800ft/sec from penetrating the ¼″ AR500 steel foundation layer. As a resultof this discovery, it was concluded that a stronger interface layer or areinforced foundation layer would be required to defeat soft lead roundstraveling in excess of 2800 ft/sec.

In all of the tests described in Test Groups 1 and 2, the variouscomponents were adhered to each other using a 3M aerosol sprayautomotive, although it is expected that a wide range of adhesives willfunction with substantially equal effectiveness.

Test Group 2:

Test Group 2 involved Samples consisting of combinations of solid sheetsof ABS plastic and Kevlar with variations in thickness and placement onthe face and/or back of the AR500 steel. 3/16″ ABS plastic layers wereused for this test, and layers were laminated to one another to achievevarying thickness ABS plastic layers. This allowed testing a more rigidinterface layer as well as a reinforced foundation layer. It wasdiscovered that a reinforced foundation layer could prevent thefracturing of the steel, or in the case of steel failure, catch thepenetrating bullet and steel debris, thus preventing total penetrationof the Sample.

It was discovered that additional layers of ABS plastic in the interfacelayer reduced penetration but alternating layers of Kevlar and ABSplastic in the interface layer was required to most effectively preventpenetration. It was also observed that bullet impacts lead to theseparation of the various layers and that ABS plastic or the combinationof ABS plastic and Kevlar were good at catching spall. All Samples wereshot with a 5.56×45 lead bullet traveling in excess of 2800 ft/sec.

Referring to FIG. 14, Sample 2.1-A (foundation layer (position reversedto be put in front to receive first impact of incoming round) comprising¼″ AR500 steel affixed atop 3 layers of 3/16″ ABS plastic backing):Projectile from a 5.56×45 lead bullet resulted in penetrated AR500 steellayer but did not penetrate ABS plastic backing—partial success.

Referring to FIG. 15, Sample 2.1-B (foundation layer (position reversedto be put in front to receive first impact of incoming round) comprising¼″ AR500 steel affixed atop 6 layers of 3/16″ ABS plastic backing). Theprojectile from a 5.56×45 lead bullet penetrated AR500 steel layer butdid not penetrate ABS plastic backing—partial success.

Referring to FIG. 16 Sample 2.1-C (interface layer comprising 3 layersof 3/16″ ABS plastic affixed atop foundation layer comprising ¼″ AR500).The projectile from a 5.56×45 lead bullet penetrated thisconstruction—relatively poor protection.

Referring to FIG. 17 Sample 2.1-D (interface layer comprising 6 layersof 3/16″ ABS plastic affixed atop foundation layer comprising ¼″ AR500steel). The projectile from a 5.56×45 lead bullet penetrated thisconstruction with reduced damage—relatively poor protection.

Referring to FIG. 18 Sample 2.2-A (interface layer comprising 3 layersof 3/16″ ABS plastic, each layer of plastic being encircled by a singleply Kevlar wrapping, interface layer assembly being affixed atopfoundation layer comprising ¼″ AR500 steel foundation layer). Theprojectile from a 5.56×45 lead bullet penetrated this construction thusresulting in a rating of relatively poor protection.

Referring to FIG. 19, Sample 2.2-B (interface layer comprising 6 layers3/16″ ABS plastic, each layer of plastic being encircled by a single plyKevlar wrapping, interface layer assembly being affixed atop foundationlayer comprising ¼″ AR500 steel). The projectile from a 5.56×45 leadbullet penetrated the interface layer, but the bullet did not penetrateAR500 steel resulting in a rating of complete success.

Referring to FIG. 20, Sample 2.3-A (interface layer comprising 3 layersof 3/16″ ABS plastic, each layer of plastic being encircled by a singleply Kevlar wrapping, interface layer assembly being affixed atopfoundation layer, foundation layer comprising ¼″ AR500 steel affixedatop 3 layers of 3/16″ ABS plastic backing). The projectile from a5.56×45 lead bullet penetrated AR500 steel layer but did not penetrateABS plastic backing—partial success.

Referring to FIG. 21, Sample 2.3-B (interface layer comprising 6 layersof 3/16″ ABS plastic, each layer of plastic being encircled by a singleply Kevlar wrapping, interface layer assembly being affixed atop afoundation layer comprising ¼″ AR500 steel affixed atop 3 layers of3/16″ ABS plastic backing). The projectile from a 5.56×45 lead bulletpenetrated interface layer, but the bullet did not penetrate the AR500steel for a rating of complete success.

Test Group 2 Conclusion: A sufficiently durable interface layer canreduce bullet velocities to prevent lead bullets traveling in excess of2800 ft/sec from penetrating a ¼″ AR500 steel foundation. Additionally,when considering partial success it is shown that semi-rigid ablativematerial not reinforced with Kevlar, such as plastic, performs betterwhen placed behind ¼″ AR500 steel than in front of ¼″ AR500 steel.Additionally, when considering complete success (¼″ AR500 steel notbeing penetrated), Kevlar reinforced plastic performs better when placedin the interface layer in front of ¼″ AR500 steel than when placedbehind. As a result of this work, it is believed that plastic in frontof the steel will help protect the steel from being penetrated becausethe plastic will reduce bullet velocity. Plastic behind the steel isalso useful because it can catch a bullet that penetrates the steel andother fragments, but may not reinforce the steel sufficiently to preventthe steel from being penetrated. More particularly, semirigid plasticwithout Kevlar in the interface layer was found not to reinforce the ¼″AR500 steel foundation layer with sufficient tensile strength to preventthe steel from fracturing under the strain of a lead bullet traveling inexcess of 2800 ft/sec.

Test Group 3:

Test Group 3 involved testing a variety of foundation layers comprisingAR500 steel encased in a variety of polyurethane based hard plastics.AR500 steel combined with reinforcements encased in plastic was alsotested. Finally, test samples comprising prototype yellow and red platesreinforced with aluminum were tested. In all cases, test samplescomprising a plastic encasement showed varying degrees of degradation inthe hard plastic encasement after just a single shot. Best results wereyielded by the samples reinforced with aluminum. All samples were shotwith a 5.56×45 lead bullet traveling in excess of 2800 ft/sec.

Referring to FIG. 22, Sample 3-A (¼″ AR500 steel plate encased withinSmooth Cast 380 Plastic made by Reynolds Advanced Materials, plasticthickness being ¼″ on the front and side with ½″ thickness on the back)5.56 lead bullet penetrated the relatively brittle plastic in thissample and shattered plastic—relatively poor protection.

Referring to FIG. 23 Sample 3-B (¼″ AR500 steel plate encased withinSmooth Cast 385 Plastic made by Reynolds Advanced Materials, plasticthickness being ¼″ on the front and side with ½″ thickness on the back)5.56 lead bullet exploded front covering, partially penetrated ¼″ AR500steel but was caught in the back plastic. Sample would not survive asecond hit.—limited success. Smooth Cast 385 appears to be a strongerplastic but still too brittle to be used to encase armor.

Referring to FIG. 24 Sample 3-C (¼″ AR500 steel plate encased withinTask 18 Plastic made by Reynolds Advanced Materials, plastic thicknessbeing ¼″ on the front and side with ½″ thickness on the back) 5.56 leadbullet blew off front plastic but did not penetrate ¼″ AR500 steel. Backplastic cracked and this test sample may not have survived a second hit,thus yielding a rating of limited success. It is believed that theeffectiveness of this arrangement, lacking as it did any conventionalbullet proofing fiber was a result of flexure of the AR 500 steel plateand resulting stretching of the half-inch thick layer of Task 18Plastic, which stretching acted to spread the energy from the impact ofthe lead projectile over the entire plastic half-inch thick back layer.It is noted that a single layer of AR 500 steel, by comparison, wasdiscovered by the inventors to be weak enough to be pierced by a leadround. Such flexing of the steel plate and associated stretching of aback layer secured to the back of the steel plate (with its absorptionof the impact of the projectile) is described below.

Referring to FIG. 25, Sample 3-D (¼″ AR500 steel plate encased withinTask 21 Plastic, plastic thickness being ¼″ on the front and side with½″ thickness on the back) 5.56 lead bullet penetrated this test sample,but with no shattering of plastic—relatively poor protection.

Referring to FIG. 26, Sample 3-E (interface layer comprising threelayered steel grill (glued to each other and other components of theprotective plate), grill layer made from a 16 gauge mild steel barbequegrill material with ¼″ diamond shaped holes, holes evenly spaced ⅛″apart across the entire grill surface, each grill layer offset slightlysuch that there was no clear path through the grill without interactingwith part of the grill, affixed atop foundation layer comprising ¼″AR500 steel plate, interface layer and foundation layer encased withinSmooth Cast 385 Plastic, plastic thickness being ¼″ on the front andside with ½″ thickness on the back) 5.56 lead bullet penetratedinterface layer but was sufficiently deflected that bullet did notpenetrate ¼″ AR500 steel plate. The layers were affixed to each otherusing glue as described herein. Front plastic immediately above impactarea was shattered but there was no damage to back plastic. Sampleremains functional. Mild steel grill noticeably altered bullettrajectory and noticeably reduced damage to Smooth Cast 385 plasticcompared with Sample 3-B where no grill was used.—success.

Referring to FIG. 27 Sample 3-F (¼″ AR500 steel plate, wrapped in andglued to an 18 gauge wire mesh with ½″ separations between wires,encased within Task 18 Plastic, plastic thickness being ¼″ on the frontand side with ½″ thickness on the back). A 5.56 lead bullet penetratedSample but plastic held together and did not break apart as in the caseof Sample 3-C which also used Task 18 Plastic.—relatively poorprotection. However, rebar effect successful since it was shown toimprove the strength of the plastic encasement and prevent plastic frombreaking apart.

Referring to FIG. 28 Sample 3-G (foundation layer comprising ¼″ AR500steel plate affixed atop ¼″ aluminum plate, foundation encased withinSmooth Cast 385 Plastic, plastic thickness being ¼″ on the front andside with ½″ thickness on the back) 5.56 lead bullet exploded frontcovering, and partially penetrated ¼″ AR500 steel and blew out the backplastic. Sample not suitable to survive repeated hits given the amountof damage observed from a single hit, however bullet wasstopped.—limited success.

Referring to FIG. 29, Sample 3-H (interface layer comprising 3 layeredsteel grill, each grill layer offset slightly such that there was noclear path through the grill without interacting with part of the grill,affixed atop foundation layer comprising ¼″ AR500 steel plate affixedatop ¼″ aluminum plate, foundation layer wrapped in a 18 gauge wire meshwith ½″ separations between wires, interface layer and foundation layerencased within Task 21 Plastic, plastic thickness being ¼″ on the frontand side with ½″ thickness on the back) 5.56 lead bullet trajectory wasaltered by grill interface layer and did not penetrate ¼″ AR500 steelplate. No damage to plastic encasement layer and target suitable tosurvive repeated hits.—complete success.

Referring to FIG. 30 Sample 3-I (Interface layer, comprising dimpledfoam affixed atop 6 layers of Kevlar affixed atop ¼″ foam, interfacelayer affixed atop foundation layer, comprising ¼″ AR500 steel plateaffixed atop ¼″ aluminum.) 5.56 lead bullet penetrated ¼″ AR500 steelplate but did not penetrate ¼″ aluminum.—partial success. 5.56 bulletshot at back of plate penetrated aluminum but did not penetrate ¼″ AR500steel plate.—partial success. Comparing to the embodiment of FIG. 21,suggests the importance of depth allowing Kevlar to stretch and perhapsthe importance of higher density material providing that depth, althoughthe environment of FIG. 21 effectively has 12 layers of Kevlar. However,comparing to the FIG. 20 embodiment, where the projectile penetratedAR500 steel layer but did not penetrate ABS plastic backing—partialsuccess.

Referring to FIG. 31 Sample 3-J (Interface layer, comprising dimpledfoam affixed atop two layers of Kevlar affixed atop ⅛″ foam, interfacelayer affixed atop foundation layer, comprising ¼″ AR500 steel plateaffixed atop ⅛″ aluminum.) 5.56 lead bullet penetrated interface layerbut did not penetrate ¼″ AR500 steel plate.—complete success. Thisresult suggests the importance of initial impact absorption byrelatively weak materials such as dimpled foam which one would have noexpectation of being able to stop the projectile, but which at highincoming projectile speeds may be very effective energy absorbers. A5.56 bullet shot at the back of the plate penetrated the aluminum butdid not penetrate ¼″ AR500 steel plate.—partial success. This resultagain suggests the importance of initial deformable or shatterablelayers absorbing energy of an incoming projectile rioted in fact withthe rigid AR 500 steel plate.

Test 3 Conclusion: Unreinforced rigid plastic is not ideal forencasement layer as it will not likely survive repeated hits withoutreinforcement. (Rigid plastic encasement is also too heavy compared toother possible solutions). As a result of a combination of deflectionand energy absorption, the steel grill configuration can affect bullettrajectory, greatly improving survivability of foundation layer.Aluminum backing is capable of supporting foundation layer inconjunction with a weaker interface layer, but needs to be secured in astronger fashion than just 3M adhesive. This is suspected because the ¼″aluminum should have performed better than the ⅛″ aluminum as it is astronger material, yet it is suspected that it partially separatedduring impact, thus reducing support of the ¼″ AR500 steel. Furthertests should confirm whether this result was an anomaly or if there areother forces at work making ⅛″ aluminum superior to ¼″ aluminum. Thebest strength to weight ratio will likely be achieved by somecombination of a Kevlar+foam interface layer affixed to a steel andaluminum foundation layer.

Test Group 4:

Test Group 4 involved testing of various configurations incorporatingAR500 steel, aluminum, Kevlar, foam, and/or rubberized encasement.

Referring to FIG. 32a Sample 4-A (interface layer comprising 8sub-interface layers affixed atop one another, (each sub-interface layercomprising a sheet of polyurethane and Kevlar composite which isavailable on the market. Affixed atop a 0.03″ sheet of polycarbonateaffixed atop a 0.06″ sheet of Ultra High Molecular Weight Polyethylene(UHMWP) FIG. 32b ) affixed atop a sheet of polyurethane enhanced Kevlar.The interface layer is affixed atop a foundation layer comprising a ¼″AR500 steel plate.): 5.56×45 lead bullet penetrated interface layer butdid not penetrate AR500 steel—complete success. 7.62×54R 185 grain FMJsteel bullet penetrated interface layer but did not penetrate AR500steel plate—complete success. It is believed that the reason for theeffectiveness of this product is a consequence of the ability of theKevlar fibers and more particularly, the Kevlar polyurethane compositeto stretch and absorbed energy. The polycarbonate backing may improveeffectiveness by deforming and fracturing allowing energy to be absorbedby the Kevlar composite.

Referring to FIG. 33a Sample 4-B (interface layer comprising 8sub-interface layers affixed atop one another, each sub-interface layer(schematically illustrated in FIG. 33b ) comprising a sheet of Kevlar(the same Kevlar material used in all of the samples tested) affixedatop a 0.03″ sheet of polycarbonate affixed atop a 0.06″ sheet of UltraHigh Molecular Weight Polyethylene (UHMWP) affixed atop a sheet ofKevlar. Interface layer was affixed atop a foundation layer comprising a¼″ AR500 steel plate). A 5.56×45 lead bullet penetrated the interfacelayer but did not penetrate AR500 steel giving a conclusion of completesuccess. 7.62×54R 185 grain FMJ steel, bullet penetrated interface layerbut did not penetrate AR500 steel plate—complete success. As in all theother sample test described herein, all layers, whether Kevlar,polymers, enhanced polymers, plastic, etc. were glued to each other(except where the nature of material formation inherently providedadhesion, i.e. in the case of Plasticdip and Smooth Cast products) usingthe automotive adhesive specified herein.

Referring to FIG. 34 Sample 4-C (interface layer comprising 3 sheets of0.06″ ultra high molecular weight polyethylene affixed atop a foundationlayer comprising a ¼″ AR500 steel plate affixed atop 4 layers of 0.06″ultra high molecular weight polyethylene. An encasement layer comprising2 overlapping layers of Kevlar wraps around the test sample.): 5.56×45lead bullet penetrated interface layer but did not penetrate AR500steel—complete success. 7.62×54R 185 grain full metal jacket steelbullet penetrated interface layer but did not penetrate AR500 steelplate—complete success.

Referring to FIG. 35 a, the inventive personnel protecting plate 810 ofSample 4-D comprises a foundation layer 812, comprising ¼″ AR500 steel.Foundation layer 812 is contained within an encasement layer. Theencasement layer comprises two front overlapping layers of Kevlarsecured by glue to the steel AR 500 plate forming foundation layer 812and was further wrapped around the steel AR 500 plate. In similarfashion, two layers of Kevlar 814 b are glued to each other and to theback of foundation layer 812. A 5.56×45 lead bullet penetrated interfacelayer but did not penetrate AR500 steel, giving this construction arating of complete success. A 7.62×54R 185 grain full metal jacket steelbullet 811 penetrated the interface layers of Kevlar 814 a but did notpenetrate the AR500 steel plate again yielding a rating of completesuccess against a full metal jacket steel projects.

Referring to FIG. 35 b, it is believed that the favorable result issubstantially provided by back Kevlar layers 814 b by their beingstretched as a result of deformation steel foundation layer 812 byincoming projectile 811. More particularly, when projectile 811 hits aportion, perhaps the central portion, of AR 500 steel foundation layer812, that portion tends to move forward, but surrounding portions of therest of the plate to stay in place because of their inertia. In thisrespect, the weight of the steel compared to the stiffness of the platehelps result in deformation. However, this deformation is largelyelastic at the moment of the initial impact. During this elasticdeformation process, the flexure of AR 500 steel foundation layer 812results in its back surface 815 having a greater circumference than itsfront surface 817. Accordingly, back Kevlar layers 814 b are stretched,and in stretching absorb the energy of incoming projectile 811.

Is believed that increasing the number of layers of Kevlar adhered tothe back surface 815 of AR 500 steel foundation layer 812 will increasethe amount of energy which can be absorbed, until a point where thenumber of layers is so large that they impede the necessary amount offlexure necessary to both absorbed energy and allow AR 500 steelfoundation layer 812 to flex and not break.

Referring to, Sample 4-E (interface layer comprising 2 layers of Kevlaraffixed atop ⅛″ layer of foam, interface layer affixed atop a foundationlayer comprising ¼″ AR500 steel plate affixed atop ⅛″ aluminum plate,the two layers of Kevlar in the interface layer wrapping around the backof the foundation layer.): 5.56×45 lead bullet penetrated interfacelayer but did not penetrate AR500 steel—complete success. 7.62×54R 185grain full metal jacket (FMJ) steel bullet penetrated interface layerbut did not penetrate AR500 steel plate—complete success. 30.06 leadbullet completely penetrated target—relatively poor protection.

Referring to FIG. 37 Sample 4-F (interface layer comprising 2 layers ofKevlar affixed atop ⅛″ layer of foam, interface layer affixed atop afoundation layer comprising ¼″ AR500 steel plate affixed atop ¼″aluminum plate, the two layers of Kevlar in the interface layer wrappingaround the back of the foundation layer.): 5.56×45 lead bulletpenetrated interface layer but did not penetrate AR500 steel—completesuccess. 7.62×54R 185 grain FMJ steel bullet penetrated interface layerbut did not penetrate AR500 steel plate—complete success. 30.06 leadbullet penetrated interface layer but did not penetrate AR500 steelplate—complete success.

Sample 4-F was shot from behind by a 30.06 lead bullet (¼″ aluminumaffixed atop ¼″ AR500 steel) and bullet completely penetrated the target-relatively poor protection, perhaps because the foam was impressed andprevented the two layer Kevlar on the front of the plate from stretchingand absorbing energy.

Referring to FIG. 38 Sample 4-G the interface layer comprised two layersof Kevlar affixed atop ⅛″ aluminum plate affixed atop ⅛″ layer of foam,interface layer affixed atop a foundation layer comprising ¼″ AR500steel plate, the two layers of Kevlar in the interface layer wrappingaround the back of the foundation layer. A 5.56×45 lead bulletpenetrated the interface layer but did not penetrate the AR500 steel fora rating of complete success. A 7.62×54R 185 grain FMJ steel bulletpenetrated the interface layer but did not penetrate the AR500 steelplate—complete success. 30.06 lead bullet partially penetratedtarget—relatively poor protection. The failure of this material toprotect against a lead projectile can be understood as a result of thestructure not providing any support which allows the Kevlar to stretch.More particularly, the Kevlar is directly glued to aluminum whichprevents it from stretching until the aluminum has been penetrated.

Referring to FIG. 39, in the case of Sample 4-H (interface layercomprising two layers of Kevlar affixed atop ⅛″ aluminum plate affixedatop ⅛″ layer of foam, interface layer affixed atop a foundation layercomprising ¼″ AR500 steel plate affixed atop ⅛″ aluminum plate, the twolayers of Kevlar in the interface layer wrapping around the back of thefoundation layer), a 5.56×45 lead bullet penetrated the interface layerbut did not penetrate the AR500 steel for a rating of complete success.A 7.62×54R 185 grain FMJ steel bullet penetrated the interface layer butalso did not penetrate AR500 steel plate for a rating of completesuccess.

Referring to FIG. 40, in the case of sample 4-I (interface layercomprising 2 layers of Kevlar affixed atop ⅛″ aluminum plate affixedatop ⅛″ layer of foam, interface layer affixed atop a foundation layercomprising ¼″ AR500 steel plate affixed atop ¼″ aluminum plate, the twolayers of Kevlar in the interface layer wrapping around the back of thefoundation layer), a 5.56×45 lead bullet penetrated interface layer butdid not penetrate AR500 steel for a rating of complete success. Hey7.62×54R 185 grain FMJ steel bullet penetrated the interface layer butdid not penetrate AR500 steel plate for a rating of complete success.However, a 30.06 lead bullet completely penetrated Sample 4-I for arating of relatively poor protection.

Test 4 Conclusion: Soft interface layer affixed atop a rigidlyreinforced foundation layer with Kevlar wrapped entirely around Sampleis the most promising protection compared to weight and thickness fordefeating soft lead rounds. Utilizing a tight Kevlar wrap around thefoundation layer greatly increases the strength of the foundation layeras well as long term durability. A primary concern seems to be keepingKevlar tightly wrapped when used behind the foundation layer as thatpromotes stretching and energy absorption by the Kevlar behind thefoundation layer and also does a better job of holding everything inplace securely. Earlier tests generally involving shock absorption atthe front end in the form of a grill or even plastic also seems to makea difference in reducing bullet impact energy. A stronger interfacelayer and a stronger foundation layer both are effective ways ofstopping high velocity bullets. Given that tests have shown severalmethods that will stop a high velocity bullet, the lighter weight optionwould be preferable. This is more about finding the right balancebetween interface layer and foundation layer options.

Test Group 5:

Test Group 5 involved further work with the goal of optimization testingof foundation layer configurations comprising ¼″ AR500 steel, possibleinclusion of aluminum, and varying amounts of Kevlar. Samples weretested against 5.56×45 lead bullets as well as tested against 30.06 leadbullets with all bullets traveling in excess of 2800 ft/sec. Each Samplewas first shot with the 30.06 lead bullet and then shot with the 5.56lead bullet. The goal of this test was to determine the lightest andleast expensive method of construction required to achieve a desiredstrength. Samples were weighed to compare against a raw ¼″ AR500 steelplate of equivalent size weighting 3 lb 7 oz.

A duplicate set of samples were made for use in optimizing armor againsthigh powered armor piercing rounds traveling in excess of 2800 ft/secbut at this time, the armor piercing test against these samples has notyet been completed. It is theorized that since lead bullets causegreater damage against AR500 steel based armors compared to damage fromarmor piercing ammunition, if an armor stops a lead bullet traveling inexcess of 2800 ft/sec, then the same AR500 steel based armor should alsobe able to stop an equivalent caliber armor piercing bullet in excess of2800 ft/sec.

Referring to FIG. 41a Sample 5-A, which with all its components weighed3 lb 14 oz, comprised ¼″ AR500 steel plate with one sheet of Kevlar 914(FIG. 41b ). Kevlar sheet 914 as a generally cross shaped figurationwith a central portion 914 a substantially matching in shape and size ofthe plate to be covered. Four portions 914 b have substantially the samesize and shape. In accordance with the invention, the central portion isglued to the front of AR 500 steel plate 912. Portions 914 b are wrappedaround and secured by being glued in position overlying the back ofplate 912. Thus, a single sheet of Kevlar 914 provides a single layer ofKevlar over the front of plate 912 and four layers of couple arecompletely covering the back of plate 112. Repeating the process bytightly wrapping a second sheet 914 to the back of plate 912 with thefirst sheet 914 already glued to it and overlapping completely over thefront with four portions 914 b results in a sample with a total of 5layers of Kevlar on the front and 5 layers on the back under tension.Under test, a 30.06 lead bullet penetrated this Sample, scoringrelatively poor protection. 5.56 lead bullet did not penetrate ¼″ AR500steel plate which was a successful outcome.

FIG. 42 shows Sample 5-B which had a weight of 4 lb 7 oz. It comprisedsubstantially similar to that of FIG. 41, except for the addition of athird piece of Kevlar tightly wrapping from front to back andoverlapping completely over the back 4 times, a fourth piece of Kevlartightly wrapping from front to back and overlapping completely over theback 4 times, and a fifth piece of Kevlar tightly wrapping from back tofront and overlapping completely over the front four times. Theresulting structure containing a total of seven layers of Kevlar on thefront and 14 layers of Kevlar on the back under tension). Upon beingimpacted with a 30.06 lead bullet the ¼″ AR500 steel plate waspenetrated but the projectile was partially caught in the Kevlar backinggiving a rating of limited relatively poor protection. Accordingly, itwas concluded that 14 layers of Kevlar caused excessive rigidity andstretching of the Kevlar with the associated absorption of energy didnot occur to a sufficient extent. 5.56 lead bullet did not penetrate ¼″AR500 steel plate, presenting a rating of complete success.

Referring to FIG. 43 Sample 5-C at a weight of 4 lb 7 oz. Itsconstruction was similar to that of FIG. 41 except for the addition ofan aluminum plate. The foundation layer comprised ¼″ AR500 steel plateaffixed atop ⅛″ aluminum plate, foundation layer being enclosed byKevlar with 1 piece of Kevlar tightly wrapping from front to back andoverlapping completely over the back 4 times with a second piece ofKevlar tightly wrapping from back to front and overlapping completelyover the front 4 times, Sample containing a total of 5 layers of Kevlaron the front and 5 layers on the back under tension): 30.06 lead bulletpartially penetrated ¼″ AR500 steel plate but was caught by the ⅛″aluminum plate incurring only minor denting. Sample can withstandmultiple hits as long as no two bullets strike the exact samespot—partial success. 5.56 lead bullet did not penetrate ¼″ AR500 steelplate—complete success.

Compared to the FIG. 41 embodiment, substantial additional strength wasachieved sufficient to withstand an incoming letter 30.06 projectile. Itis believed that tightly wrapping the Kevlar layers promoted transfer ofenergy to the aluminum layer, which even though it was only 0.125 inchesthick and substantial beneficial effect on the outcome. The thinness ofthe aluminum may be promoting stretching of the aluminum conforming toflexure of the steel plate in response to the tendency of the steelplate to increase its back circumference and stretch layers behind it.

Test 5 Conclusion: A tight wrap of Kevlar can reinforce ¼″ AR500 steelwell enough to withstand the 5.56 lead bullet. A sufficient amount ofKevlar could stop the 30.06 bullet from completely penetrating theSample, but probably cannot ever be a strong enough reinforcement toprevent the ¼″ AR500 steel plate from being penetrated. Additionally, ⅛″aluminum backing is sufficient to prevent total penetration of the 30.06bullet when foundation layer is tightly wrapped in Kevlar, weighing lessand costing less to produce than an all Kevlar reinforcement solution.Tightly wrapping foundation layer in Kevlar appears to greatly improvethe strength of foundation layer materials and prevents foundation layermaterials from separating when receiving incoming bullets.

The above work appeared to indicate that it is important to overlaplayers of Kevlar so that there are no exposed seams on the back and thatlayers reinforce each other.

OVERALL CONCLUSIONS

Given certain market limitations in space, weight, and cost, when itcomes to personal body armor trauma plates, it appears that thethinnest, lightest, and least costly method for stopping both armorpiercing, steel, and lead bullets is to utilize a combination ofinterface layer affixed atop a foundation layer, with interface layerand foundation layer encapsulated within an encasement layer. However,testing is planned to confirm whether protection is being provided byfront or back layers of Kevlar. A preferred embodiment comprises thelayers providing protection covered by a single all-around ply of Kevlarto keep all elements in place. In accordance with a particularlypreferred embodiment, such Kevlar will be use with a foundation layercomprising steel and aluminum layers, including most preferablyembodiments with steel in the front. Tests putting aluminum in frontappeared to indicate that it is preferable to position an aluminum layerbehind a steel. Moreover, flexure of the forward facing steel layer intoan arcoate shape with resultant stretching of the aluminum layer isbelieved to be a particularly effective strategy for absorbing energyand distributing it over the entire layer.

Optimal Outer Encasement Layer: Plastidip over dimpled foam since itadequately weather seals the armor plate and, for the most part, tendsto self seal when penetrated by most bullets (probably due to the bulletheat melting the foam and plastidip causing it to reform over the hole.It is contemplated that this outer encasement layer will overliemultiple plies of Kevlar encasing the steel/aluminum-steel foundationplate.

Optimal interface Layer: Interface layer comprising two components, aprimary interface layer affixed atop a secondary interface layer,primary interface layer comprising 1-2 layers of Kevlar affixed atop⅛″-¼″ foam, with Kevlar wrapping around the sides and partially aroundthe back of armor plate, and secondary interface layer comprising layersof Kevlar tightly wrapping around foundation layer. The primaryinterface layer helps reduce bullet velocity and catches any debris andspall that bounces back through the secondary interface layer. The mainfunction of the secondary interface layer, comprising a Kevlar wrapwhich surrounds the foundation layer, is to help hold foundation layerelements together under tension so foundation layer elements don'tseparate when absorbing damage, thus greatly enhancing strength. Beingpart of the interface layer, the Kevlar wrap also assists with catchingspall and debris and, to some degree, helps reduce bullet velocity,though reducing bullet velocity may not be the most important of theKevlar wrap.

To the extent possible it is preferable to alternate directions ofwrapping so that a solid piece of Kevlar lays across any overlaps andseams. Two overlapping Kevlar wraps are sufficient but additional wrapswill enhance strength and durability. Additional layers also serve as astronger safety net in case the foundation layer is breached by a bulletas most of the bullet's velocity will have been absorbed by that point.Orienting the Kevlar fiber in different directions is also advantageous.This, combined with wrapping the Kevlar such that there is no uncovered(which would create a weak spot) yields superior protection. This can beimplemented in various ways. For example, if one starts a wrap on oneedge, one should wrap all the way around, overlap, and finish on theopposite edge so that there is no exposed seam. Furthermore, havingadditional Kevlar behind the plate not only reinforces the plate (thetensile strength helps prevent the steel plate from fracturing and holdseverything together) but in the event that a bullet does penetrate thesteel foundation layer, the Kevlar backing catches the bullet

Optimal Foundation Layer: It has been demonstrated that ¼″ AR500 steelplate affixed atop a ⅛″ aluminum plate is sufficient to stop a 30.06lead bullet traveling in excess of 2800 ft/sec and would provide thelightest and least expensive foundation layer. Foundation layers,referring to the rigid layer of solid plates towards the back of thearmor, are desirably made of metal such as AR500 steel and aluminum,though durable plastics that won't shatter upon receiving a highvelocity impact are also an option. The combination of a ¼″ AR500 steelplate backed by ⅛″ or thicker aluminum appears to be preferred fromalong the various sample configurations tested. A ¼″ AR500 steel plateaffixed atop a ¼″ aluminum plate will increase cost (double materialcost for aluminum but the same labor cost) and weight but will improvethe durability of the foundation layer with regard to multiple hits inthe same location. Strength added by aluminum plates exceeding ¼″thickness will not be significant compared to the additional weight,thickness, and cost to produce when attempting to stop common bulletsranging in diameter from 5.56 mm through 7.62 mm.

It should be noted that NIJ Level 4 certification levels were achievedwithout the use of aluminum reinforcement in the foundation layer andplates reinforced with aluminum are also expected to pass NIJ Level 4.It is also likely that a thinner interface layer will still allow forthe inventive armor to achieve NIJ Level 4, given the inclusion ofaluminum in the foundation layer.

Optimal Curve: A flat armor plate allows for a better bonding of thematerials comprising the foundation layer as there will be no gapbetween the AR500 steel plate and the aluminum plate. A flat armor plateallows for a tighter Kevlar wrap and a more consistent productionquality. Curve to better fit the human body can be achieved by employinga piece of foam comprising a flat surface facing the armor plate and aconcave surface facing the human body. This method also allowsutilization of varying sizes of foam for different body types.Additionally, foam will help reduce impact trauma.

It is understood that variations from the disclosed embodiments may bemade by those of ordinary skill in the art. Such variations may include,for example different foam, rubber, or additions to the Kevlar such aspolyurethane or spray on plastics such as truck bedliner to improverigidity. Additional tests will focus on reducing weight, perhapsthrough the use of less Kevlar, or the use of alternative materials tothe AR500 steel. When protecting non-vital areas of the body, it may notbe necessary to stop all high caliber bullets, but rather focus onabsorbing damage from debris and shrapnel using reduced weightmaterials, and, accordingly, inventive structures which are not at thehighest protection levels may be preferred. It may also be possible tobuild lighter armor that, instead of stopping all bullets, stops onlythe most common bullets used by expected adversaries (such as the7.62×39 bullet used in the AK47) allowing for a lighter weight andthinner steel used in the foundation layer.

Optimal Configuration Summary

A foundation layer, whether a single AR500 steel plate or severalmaterials used in conjunction therewith, is, in accordance with what iscurrently believed to be the best mode of the invention, preferablycontained within a tight Kevlar wrap which extends completely around thefoundation layer, most preferably with substantial overlap, for exampleover the back of the foundation layer. When utilizing a foundation layercomprising multiple components, best results may often be achieved whenfoundation layer components are arranged such that incoming bulletsfirst encounter the strongest material first, for example a layer ofKevlar supported by a flexible material which allows the Kevlar tostretch and begin to absorb impact energy. Other materials in thefoundation layer then serve as support for the strongest layer, perhapsacting as both a reinforcement to the first layer, and also serving as asafety net should an incoming bullet penetrate the first layer.

The inventive interface layer may desirably comprise a fibrous mesh,such as Kevlar, over an ablative polymer layer, such as foam, rubber, orplastic. The inventive interface layer should they also advantageouslyinclude a Kevlar layer that tightly wraps around the outer surface ofthe foundation layer, ideally in several directions, thus providingadditional strength and support. Augmenting Kevlar with a polymercoating such as polyurethane makes the Kevlar more rigid anddemonstrates some benefit by not allowing Kevlar fibers to separate aseasily.

Encapsulation layer should comprise a softer, less rigid, weatherproofpolymer material, such as Plastidip, truck bedliner, or cast plastic orrubber. It is important that encapsulation material not be brittle asthe primary purpose is to protect inner layers from wear and tear, notstop bullets. A durable soft rubberized material seems to work best.˜˜˜

Referring to FIG. 50, an improved armor encasement dipping method may beunderstood. A cloth ribbon assembly 710 comprising an outer ribbon 712,an inner ribbon 714, a hook loop 716 and a stitching fold 718, iscoupled to foundation layer 720 comprising an outer foundation surface722, an inner foundation surface 724, and a foundation edge 726, usingan adhesive 728, forming a combined foundation assembly 730. Outerribbon 712 is affixed to outer foundation surface 722 using adhesive728. Inner ribbon 714 is affixed to inner foundation surface 724. Toprevent separation of ribbon assembly 710 from foundation layer 720,stitching fold 718 is positioned at foundation corner 732, foundationcorner 732 being the intersection of inner foundation surface 724 andfoundation edge 726, where outer ribbon 712 leaves no empty spacewrapping across foundation edge 726 before affixing to outer foundationsurface 722. Ribbon assembly 710 is made from material strong enough tosupport the weight of combined foundation assembly 730. Hook loop 716creates a hook encirclement space 734 which is large enough to allow adipping hook 736 to be easily inserted into hook encirclement space 734during an encasement layer dipping process 738.

Referring to FIG. 51, a preferred method for an encasement layer dippingprocess 738 may be understood. An armor plate assembly 740 comprisescombined foundation assembly 730, which may or may not have beenaugmented by other previously mentioned processes, prior to encasementlayer dipping process 738. Dipping hook 736 is inserted into hookencirclement space 734 with an orientation such that armor plateassembly 740 hangs from and below dipping hook 736, such that dippinghook 736 is solely supporting the weight of armor plate assembly 740.Dipping hook 736 is positioned such that armored plate assembly 740 issuspended above encasement material container 742, said encasementmaterial container 742 having a top oriented opening 744, said opening744 being large enough for armor plate assembly 740 to pass through andsaid encasement material container 742 being large enough for armorplate assembly 740 be lowered entirely inside encasement materialcontainer 742 without making contact with any sides or bottom.Encasement material container 742 is filled with encasement material 746to a dept sufficient that armor plate assembly 740 can be completelysubmerged armor plate assembly 740 is fully lowered inside of encasementmaterial container 742.

Referring to FIG. 52, an alternate preferred method for an encasementlayer dipping process 748 may be understood. Much as in encasement layerdipping process 738, armor plate assembly 740 comprises combinedfoundation assembly 730, comprising at least one additional ribbonassembly 710. The ribbon assemblies 710 are spaced to evenly distributethe weight of armor plate assembly 740 when being suspended belowdipping hooks 736. In a method similar to that described in FIG. 202,dipping hooks 736 are inserted into hook encirclement spaces 734 with anorientation such that armor plate assembly 740 hangs from and belowdipping hooks 736, such that dipping hooks 736 are solely supporting theweight of armor plate assembly 740. Dipping hooks 736 are positionedsuch that armored plate assembly 740 is suspended above encasementmaterial container 742, with the encasement material container 742having a top orientated opening 744, the opening 744 being large enoughfor armor plate assembly 740 to pass through and said encasementmaterial container 742 being large enough for armor plate assembly 740be lowered entirely inside encasement material container 742 withoutmaking contact with any sides or bottom. Encasement material container742 is filled with encasement material 746 to a dept sufficient thatarmor plate assembly 740 can be completely submerged armor plateassembly 740 is fully lowered inside of encasement material container742.

Depending on the composition of above mentioned encasement material 742,and the composition of adhesive 728, adverse reactions betweenencasement material 742 and adhesive 728 can occur which can weaken orbreak down adhesive 728. In order to prevent this occurrence, a plasticwrapping process 750 is applied to armor plate assembly 740 prior todipping process 738. Tests have shown that, in every instance, thisprevents any potential breakdown of adhesive 728 and additionallyrequires less encasement material 742 to be used, thus reducing overallweight by a small amount.

Referring to FIG. 53, a preferred method for plastic wrapping process750 may be understood. Plastic wrapping process 750 is a process bywhich armor plate assembly 740, comprising an inner armor plate assemblysurface 752 and an outer armor plate assembly surface 754 is encasedwithin inner plastic wrap 756 and outer plastic wrap 758. Inner plasticwrap 756 and outer plastic wrap 758 can be made from any thin andflexible plastic sheet, although in the preferred embodiment, commonkitchen plastic wrap is used. Because common kitchen plastic wrap tendsto adhere to itself, no adhesive is required prior to dipping process738. Inner plastic wrap 756 is affixed to inner armor plate assemblysurface 752 with excess material being wrapped around onto outer armorplate assembly surface 754. Next, outer plastic wrap 758 is affixed toouter armor plate assembly surface 754 with excess material beingwrapped around onto inner armor plate assembly surface 752, forming awrapped armor plate assembly 760.

In certain circumstances, spall protection may be crucial for stoppingbullet fragments from ricocheting after being deflected or shattered byarmor plate assembly 740. Such fragments are known as spall. While thefundamental elements of armor plate assembly 740 are already effectiveat stopping most spall, tests have shown that this can be improved byhaving a final spall wrap 762. Such a final spall wrap 762 can providean additional layer of spall protection which wraps around the sides inorder to stop sideways deflection. In the preferred embodiment, Kevlaris used. It is also desirable to optimize the geometry of spall wrap 762to minimize material to reduce weight.

Referring to FIG. 54, a preferred method for spall protection wrappingmay be understood. Spall wrap 762 is made from a durable fibrous meshmaterial, such as Kevlar in the preferred embodiment, comprising acenter spall guard 764 and a number of spall guard tabs 766, the numberof spall guard tables 766 corresponding to the specific geometry of agiven armor plate assembly 740, numbering 6 spall guard tabs 766 in thepreferred embodiment. Spall guard 764 is affixed to outer foundationsurface 722 by means of adhesive 728, with an orientation such that theentire outer foundation surface 722 is exactly covered by spall guard764. Spall tabs 766 protrude beyond outer foundation surface 722 in sucha way that spall tabs 766 may wrap behind combined foundation assembly730 and are affixed to inner foundation surface 724 by means of adhesive728.

Referring to FIG. 55, a preferred method for applying a Kevlarreinforcement wrap 768 to a foundation layer 720 may be understood.Foundation layer 720, in the case of a preferred embodiment, is shapedto fit a typical human torso and comprises a top edge 770, a bottom edge772, a right edge 774, a left edge 776, a right shoulder edge 778, and aleft shoulder edge 780. In a preferred embodiment, a vertical Kevlarreinforcement wrap 782 is affixed to foundation layer 720, by means ofadhesive 728, in a vertical orientation such that the wrap crosses theouter foundation surface 722, wraps behind to cross the inner foundationsurface 724, and then wraps around to cross the outer foundation surface722 a second time. A second vertical Kevlar reinforcement wrap 782 isalso affixed atop the first vertical Kevlar reinforcement wrap 782 foradditional strength. The two vertical Kevlar reinforcement wraps 782 areapplied in opposing directions such that the two vertical Kevlarreinforcement wraps 782 support one another. Next, two left shoulderreinforcement wraps 784 and two right shoulder reinforcement wraps 786are affixed to foundation layer 720, by means of adhesive 728, such thatleft shoulder reinforcement wraps 784 and right shoulder wraps 786 beginin the middle of outer foundation surface 722, wrap across right edge774 and left edge 766 respectively, and around to inner foundationsurface 724. Finally, three horizontal reinforcement wraps 788 areaffixed to foundation layer 720, by means of adhesive 728, in ahorizontal orientation such that each horizontal reinforcement wrapcrosses the outer foundation surface 722, then wraps behind to cross theinner foundation surface 724, and then wraps around to cross the outerfoundation surface 722 once again. The horizontal reinforcement wraps788 alternate beginning and ending on either the right edge 774 or theleft edge 776, with each of the three horizontal reinforcement wraps 788atop one another for additional strength, The three horizontalreinforcement wraps 788 are applied in opposing directions such thateach horizontal reinforcement wrap 788 supports one another.

Turning next to FIGS. 56 and 57, a further alternative embodiment of theinventive personnel protecting plate 1010 is illustrated. In thisembodiment, a foundation plate is formed by a 0.25 inch thick AR 500steel plate 1012 which is adhered to a 0.125 inch aluminum plate 1011. AT-shaped Kevlar sheet as illustrated in FIG. 57 forms a front Kevlarlayer 1001, a rear pair of Kevlar layers 1002 and 1003, and a third rearKevlar layer 1004. The Kevlar sheet of FIG. 57 is applied to thefoundation plate formed by steel layer 1012 and aluminum layer 1011 bygluing the central portion 1001 of the Kevlar sheet to the front of thefoundation plate. Portions 1002 and 1003 are then wrapped around thefoundation plate and sequentially glued to the back of the foundationplate. Next third layer of Kevlar 1004 is wrapped around foundationplate aluminum back 1011 and glued in place by being adhered to portion1003. Additional rigidity may be insured by extending the dimension ofportions 1002, 1003, and 1004 to include extension portions 1005, 1006and 1007. Extension portions 1005, 1006 and 1007 may be wrapped aroundthe edge of the foundation plate and glued over the Kevlar covering thefront of the foundation plate. Following this, a 0.25 inch layer offoam, rubber or ABS plastic may be applied to the front face of Kevlar1001. Finally the entire assembly is covered with a Kevlar encasement1016. In this embodiment, foam 1008 serves the function of allowingKevlar front face 1016 to deform in response to an incoming projectile1017.

While illustrative embodiments of the invention have been described, itis noted that various modifications will be apparent to those ofordinary skill in the art in view of the above description and drawings.Such modifications are within the scope of the invention which islimited and defined only by the following claims.

What is claimed:
 1. A protective device for protecting an individualfrom oncoming projectiles, comprising: (a) a substantially rigid memberhaving a length and a width sufficient to overlie a portion of the bodyof the individual to be protected, said substantially rigid memberhaving a front side oriented toward an incoming projectile and a reverseside in facing relationship to said portion of the body of theindividual to be protected, said substantially rigid member beingconfigured to spread out energy from said incoming projectile to aplurality of points on said portion of the body of the individual to beprotected; (b) an energy absorbing member; and (c) a support member forsupporting said energy absorbing member on said substantially rigidmember at a position where energy from an oncoming projectile istransferred to and absorbed by said energy absorbing member. 2.Apparatus as in claim 1, wherein the energy absorbing member comprisesan energy absorbing material which deforms resiliently and/ornon-resiliently in response to applied force.
 3. Apparatus as in claim2, wherein said substantially rigid member is elastic, and the energyabsorbing member is supported adjacent the reverse side of saidsubstantially rigid member, whereby an increase in dimension of saidreverse side of said substantially rigid member in response to flexureof said substantially rigid member being hit by an incoming projectilehitting said front side of said substantially rigid member, causes anincrease in dimension in said energy absorbing member.
 4. Apparatus asin claim 1, further comprising a spacing member positioned over andsecured to said front side of said substantially rigid member, andwherein the energy absorbing member is secured in place disposed oversaid spacing member, whereby incoming projectiles impacting said energyabsorbing member deform said energy absorbing member and proceed intothe space occupied by said spacing member before said incomingprojectiles can directly impact said substantially rigid member. 5.Apparatus as in claim 1, wherein the energy absorbing member is securedin place disposed over said substantially rigid member, whereby incomingprojectiles impacting said energy absorbing member deform said energyabsorbing member before said incoming projectiles can directly impactsaid substantially rigid member.
 6. Apparatus as in claim 1, wherein theenergy absorbing member is secured in place disposed over the front ofsaid substantially rigid member.
 7. Apparatus as in claim 1, whereinsaid energy absorbing member comprises a material selected from thegroup consisting of Kevlar, Nomex and other aramid fibers, and Spectra,Dyneema and other ultrahigh molecular weight polyethylene fibers; andsaid substantially rigid member is selected from the group consisting ofmetal plate and ceramic armor plate.
 8. Apparatus as in claim 1, whereinthe energy absorbing member comprises a first energy absorbing fiberstructure which deforms resiliently and/or non-resiliently in responseto applied force and wherein said substantially rigid member is elastic,and the energy absorbing member is supported adjacent the reverse sideof said substantially rigid member, whereby an increase in dimension ofsaid reverse side of said substantially rigid member in response toflexure of said substantially rigid member being hit by an incomingprojectile hitting said front side of said substantially rigid member,causes an increase in dimension in said energy absorbing member, andwherein said support member comprises a second energy absorbing fiberstructure, said first energy absorbing fiber structure being integralwith said second energy absorbing fiber structure, said first energyabsorbing fiber structure and said second energy absorbing fiberstructure being formed by winding or wrapping a single energy absorbingfiber fabric around said substantially rigid member.
 9. Apparatus as inclaim 1, further comprising a foam spacing member positioned over andsecured to said front side of said substantially rigid member, andwherein the energy absorbing member is secured in place disposed oversaid spacing member, whereby incoming projectiles impacting said energyabsorbing member deform said energy absorbing member and proceed intothe space occupied by said spacing member before said incomingprojectiles can directly impact said substantially rigid member. 10.Apparatus as in claim 1, further comprising a solid polymeric spacingmember positioned over and secured to said front side of saidsubstantially rigid member, and wherein the energy absorbing member issecured in place disposed over said spacing member, whereby incomingprojectiles impacting said energy absorbing member deform said energyabsorbing member and proceed into the space occupied by said spacingmember before said incoming projectiles can directly impact saidsubstantially rigid member.
 11. Apparatus as in claim 1, wherein theenergy absorbing member comprises a metallic energy absorbing materialwhich deforms resiliently and/or non-resiliently in response to appliedforce, and wherein said substantially rigid member is elastic, theenergy absorbing member being supported adjacent the reverse side ofsaid substantially rigid member, whereby an increase in dimension ofsaid reverse side of said substantially rigid member in response toflexure of said substantially rigid member being hit by an incomingprojectile hitting said front side of said substantially rigid member,causes an increase in dimension in said energy absorbing member. 12.Apparatus as in claim 1, further comprising a spacing member positionedover and secured to said front side of said substantially rigid member,and wherein a first portion of the energy absorbing member is secured inplace disposed over said spacing member, whereby incoming projectilesimpacting said energy absorbing member deform said energy absorbingmember and proceed into the space occupied by said spacing member beforesaid incoming projectiles can directly impact said substantially rigidmember, and wherein a second portion of the energy absorbing member issupported adjacent the reverse side of said substantially rigid member,whereby an increase in dimension of said reverse side of saidsubstantially rigid member in response to flexure of said substantiallyrigid member being hit by an incoming projectile hitting said front sideof said substantially rigid member, causes an increase in dimension insaid energy absorbing member.
 13. Apparatus as in claim 1, furthercomprising a second substantially rigid member oriented at an anglebetween 20 degrees and 100 degrees to said substantially rigid member,said substantially rigid members being made of steel.
 14. Apparatus asin claim 1, wherein said substantially rigid member comprises AR500steel or the equivalent.
 15. A protective device for protecting anindividual from oncoming projectiles, as in claim 1, wherein said energyabsorbing member wraps around said substantially rigid member and saidsupport member for supporting said energy absorbing member and saidenergy absorbing member are formed by a single member wrapped aroundsaid substantially rigid member substantially without any slack.
 16. Aprotective device for protecting an individual from oncomingprojectiles, as in claim 15, wherein said energy absorbing member has aT configuration formed by a central portion and three arms.
 17. Aprotective device for protecting an individual from oncomingprojectiles, as in claim 15, wherein said energy absorbing member has across configuration formed by a central portion and four arms.
 19. Aprotective device for protecting an individual from oncomingprojectiles, as in claim 15, wherein said energy absorbing membercomprises Kevlar® or another aramid synthetic fiber, or a high strengthfilm such as polyparaphenelynebenzobisthiazole film, or ultrahighmolecular weight polyethylene fiber.
 20. A protective device forprotecting an individual from oncoming projectiles, as in claim 1,wherein said energy absorbing member comprises metal wire mesh-likematerial.